Method of making breaker bands for pneumatic tires

ABSTRACT

An improved method of making breaker bands for pneumatic tires which includes spiraling successive sheets of rubberized tire cord fabric or material over a building drum to form a sleeve of desired diameter and circumferentially cutting the sleeve into breaker bands of desired width.

United States Patent [1 1 Menough et al. p

METHOD OF MAKING BREAKER BANDS FOR PNEUMATIC TIRES Inventors: Richard M. Menough; Robert W. Cuddigan, both of Denver, Colo.

Assignee: The Gates Rubber Company,

Denver, Colo.

Filed: Jan. 28, 1971 Appl. No.: 110,688

U.S. Cl 156/127, 156/129, 156/130,

156/142, 156/193, 156/426 Int. Cl B29h 17/28, B29h 17/30 Field of Search 156/123, 126, 127,

References Cited UNITED STATES PATENTS Emanueli et a1 152/361 [451 Aug. 7, 1973 1,708,129 4/1929 Gammcter 156/426 3,218,209 11/1965 Travers et a1 156/127 X 3,518,140 6/1970 Smithkey 156/123 FOREIGN PATENTS OR APPLICATIONS 558,256 12/1943 Great Britain [56/142 Primary ExaminerRalph S. Kendall Assistant Examiner-C. B. Cosby Atlorney-Raymond Fink, H. W. Oberg, Jr. and Curtis H. Castleman, Jr.

[57] ABSTRACT An improved method of making breaker bands for pneumatic tires which includes spiraling successive sheets of rubberized tire cord fabric or material over a building drum to form a sleeve of desired diameter and circumferentially cutting the sleeve into breaker bands of desired width.

9 Claims, 4 Drawing Figures PAIENIEB N15 7375 SHEEIIBFZ 2 INVENTORS RICHARD M. MENOUGH ROBERT W. CUDDIGAN BY 3 7664 AT TOR NE Y PATENIED 71973 3.751.316

SHEET 2 0F 2 l |\l\/ E [\l TC) RS= RICHARD M. MENOUGH ROBERT W. CUDDIGAN BY ,Z/fl

AT TOREE? METHOD OF MAKING BREAKER BANDS FOR PNEUMATIC TIRES BACKGROUND OF THE INVENTION The invention relates to pneumatic tires, but more particularly, the invention relates to a method of making breaker bands or strips for inclusion in pneumatic tires.

in known tire constructions, breaker bands are used between the outermost ply of the carcass and the tread portion of the tire. The breaker band reinforces and supports the tread portion while reducing tread wear and enhancing performance of the tire. Breaker bands of two or more plies are normally used as a tread reinforcement in both radial and bias ply tires.

Uniformity and alignment of the breaker band within the tire are important factors that affect operating characteristics of a tire. Should the breaker band be skewed with respect to the equatorial plane of the tire, the tire will have a tendency to wobble while rotating. Should the breaker band be of variable width or have somewhat scalloped edges, irregular wearing or flatspotting at the edge of the tire results] The breaker band may be eccentrically located in the tire because of irregular angles of the breaker band cords. The irregular angles cause uneven pantographing of the breaker band cords as the tire is formed during curing. When uneven pantographing occurs, the breaker band locates eccentrically in the tire. The eccentric breaker band then induces bad radial runout or a thumping of the tire as it is rotated. Overlapping the plies within the breaker band causes a variation in cord density. An irregular cord density induces flexure irregularity in the tire. The flexure irregularity may result in carcass separations or in a rough tire ride.

Prior art methods of making breaker bands characteristically cause the aforementioned irregularities to occur. Some prior art methods require the breaker band to be constructed concurrently during assembly of a green tire. Other methods assemble breaker bands on a flat green tire and then pantograph the reinforcement while shaping the tire into a torriod.

SUMMARY OF THE INVENTION The invention is primarily directed toward manufacturing breaker bands which are uniform in construction and substantially free of irregularities. The breaker bands of the invention are made as-a separate article of manufacture for later inclusion into an uncured or green" pneumatic tire. The method of manufacturing the breaker bands include spiraling sheets of rubberized tire cord in successive layers and in a helical manner around a building drum. Successive layers of sheet material are'spiraled as opposite helices. The plied layers of cord material define a sleeve which may be circumferentially cut into breaker bands of desired width. The breaker bands may be stored, shipped or immediately included into the manufacture process of a green pneumatic tire.

It is the object of the invention to provide a method of manufacturing breaker bands.

Another object of the invention is to provide a method of making a breaker band which is free of cord overlap.

Another object of the invention is to provide a method of making breaker bands which are substantially free of cord angle variations.

Yet another object of the invention is to provide a method of making breaker bands of uniform width.

Still another object of the invention is to balance the production time required to make a breaker band against the time required to assemble a tire carcass.

Another object of the invention is to provide a breaker band as a separate article of manufacture distinct of a tire.

Yet another object of the invention is to provide a belt of uniform diameter.

Another object of the invention is to provide a breaker band of uniform trapezoidal cross section.

Another object of the invention is to provide a pneumatic tire incorporating the breaker band of the invention.

These and other objects and advantages of the invention will become apparent upon review of the drawings and description thereof wherein:

FIG. I shows sheets of, rubberized tire cord fabric being spirally wrapped around a building to form a fabricated sleeve ready for cutting.

FIG. 2 is a view of a sheet of pre-cut rubberized tire cord.

FIG. 3 is a partial sectional isometric view of a breaker band.

FIG. 4 is a cross sectional view of a pneumatic tire incorporating the breaker band of the invention.

DESCRIPTION OF PREFERRED EMBODIMENT Breaker reinforcements are used between the outermost ply and tread of a tire carcass. The breaker reinforcement comprises plied sheets or layers of rubberized cord fabric or material that is formed into an endless band. Throughout this disclosure, the term cord includes cord, cable, wire or the like, as typically used as a reinforcement for tires. The cords are generally oriented symmetrically to form an angle with the equatorial plane of the breaker band. The angle is generally between 6 and 25 and is known as the breaker angle.

In accordance with the invention, a breaker band 10 is fabricated by spiraling successive sheets 12 of rubberized cord fabric helicallyaround abuilding drum 14 of desired diameter as shown in FIG. 1. The diameter of the drum corresponds to the desired inside diameter of the uncured or green breaker band. Rubberized fabric is spiraled at a helical angle A which is complementary to the desired breaker angle. The cumulative width W of the rubberized fabric is chosen so the edges of the fabric are adjacent or touching 16 but not overlapping. Any number of strips may be used to achieve a desirable cumulative width W. A second layer of rubberized fabric 12 is then spiraled over the first fabric layer. Usually, it is desirous to spiral and ply successive layers at an opposite but equal helical angle B to achieve some type of structural balance within the breaker band. However, successive layers of rubberized fabric I2 may be plied to achieve any desired structure. When the sheetsof rubberized fabric are plied around the drum, the cords of the fabric are slightlytensioned T by pulling the fabric longitudinally. Since the application of force is longitudinal, there is no necking down or pantographing of the fabric. Consequently, the fabric cords remain generally equidistant from each other. In prior art methods, rubberized fabric is plied by applying a force along the bias of the fabric. Application of a bias force may cause irregular necking down or pantographing when fabric cords are irregularly displaced.

The strips 12 of rubberized fabric cord may be advantageously pre-cut prior to the step of spiraling on the building drum. Pre-cutting facilitates repeatedly spiraling the fabric at a desired helical angle around the building drum 14 without the aid of special aligning equipment. For this reason, bias cutting strips of fabric is preferred. Refering to FIG. 2 a strip 18 of rubberized cord material'or fabric is prepared by bias cutting. Fabric is bias cut at an angle C that is approximately equal to the desired breaker angle. The length L of the strip 18 corresponds generally to the helical length of the drum at the desired helical angle. The width W of the strip 18 is such that the length of the bias cut edge 20 equals the circumference of the building drum 14 or the cumulative diameter of the drum and the preceding ply. Several widths of narrow fabric may be adjacently arranged to achieve a desired width W although it is preferred to use just one width of fabric. The strip 18 of bias cut rubberized fabric is placed on the drum by aligning the cut edge'20 of the fabric with a circumferential edge or reference line of the drum 14. The fabric I8 is spiraled and plied as previously explained. By aligning the cut edge of the fabric with the drum, the resulting helical angle of the fabric A,B in relation to the drum is accurately controlled. This is because the breaker angle C and the helical angles A,B are complementary. It should be noted here that when prior art rubberized fabric is bias cut into narrow bands, the uncut edges are overlapped and pressed together to form longer bands of bias fabric. Overlapping concentrates a few cords causing an irregularity. There are no such cord irregularities in fabric strips bias cut in accordance with the invention.

Uncured rubber materials are inherently cohesive. When successive strips of rubberized fabric cord are plied together by spiraling, the strips cohere forming a cylindrical sleeve 22 of plied material. Optionally, pressure may be applied to the sleeve as desired to enhance cohesion between the plies. Application of pressure to the sleeve is known in the rubber fabricating art as stitching." After the cylindrical sleeve 22 of plied material has been fabricated, it is ready for cutting.

Thesleeve 22 of plied material is circumferentially cut 24 with a cutter 26 to form breaker bands ofpredetermined width 28. The building drum 14 or cutter 26 maybe rotated in relation to each other. Preferably,

the drum 14 is rotated. Any number of cutters 26 may be used and positioned at any desired angle in relation to the outside surface of the sleeve. It is preferred that at least a pair of cutters 26 be used and set a fixed distance apart. The pair of cutters balance the cutting forces transferred to the band 10 during the cutting process and thus eliminates any tendency to move the band. Also, dual cutters facilitate producing breaker bands of exacting widths 28.

Referring to FIGS. 1 and 3, it has been found desirable to cut 24 the sleeve 22 into breaker bands 10 of substantially trapezoidal cross section 30, wherein the acute angles 32 of the trapezoid are preferably between 22 and 50. In the cutting process, the cords of breaker band are bevel cut 34 to form the trapezoidal cross section 30. This gives the breaker band substantially unimanufacturing process, the breaker bands may be shipped to other facilities stored or directly included as part of a pneumatic tire. It is readily understood that the production rate of making breaker bands may be advantageously balanced against the production rate of fabricating the carcasses.

The above described method results in the production of breaker bands 10 that are substantially free of irregularities and have unique cut edges. The outside edges 36 of the breaker band 10 lie in pseudo-parallel planes. Because of this, the band 10 has a substantially constant and uniform trapezoidal cross section 30 throughout its circumference. The parallel edges 36 of the band provide a reference means for aligning the band accurately within an uncured or green" tire.

When a breaker band 10 of the invention is to be included in a tire, a green tire carcass is fabricated in a usual manner and expanded or formed into a toroidal shape. A breaker band is aligned with and united to the carcass. Next, a tread portion is applied over the breaker band and then the tire is molded and cured under heat and pressure. As part of the molding process, the cords of the breaker band are usually pantographed or slipped to a smaller breaker angle. The uniform breaker band construction assures uniform pantographing or slipping of the cords. The breaker angle change varies with the tire design. The change in breaker angle must be considered and included when establishing the helical angle for spiraling strips of rubberized fabric as previously discussed in relation to FIG. 1 and 2.

Refering to FIGS. 2 and 4 breaker bands constructed in accordance with the invention, impart desirable characteristics to tires 38 in which they have been incorporated. The bevel cut cords 34 and pseudo-parallel edges 36 allow the outermost plies 40 of the breaker band to be extended to near the circumferential edge 42 of the tire. The extension of the outermost plies provides greater area of support for the tread portion 44. This has the effect of eliminating irregular tread edge wear. Also, the bevel cut breaker band cords 34 provide a somewhat linear or smooth transition section between the edgeof the tire tread and the breaker band. The smooth transition section promotes even wearing of the tread edge apparently because of the continuity of support which is provided.

The foregoing detailed description was made for purpose of illustration only and is not intended to limit the form beveled edges, the benefit of which will be later 6 explained. After the breaker bands 10 have been cut, they are removed from the drum. From this level in the scopeof the invention which is to be determined from the IPended claims. 'i

What. is claimed is: l. A method of making breaker bands forpneumatic tires comprising the steps of:

bias cuttingstrips of rubberized tire cord fabric at a predetermined angle,.the strips having predetermined widths; arranging a first strip of said fabric around a building drum by aligning the biased cut edge of said first strip essentially parallel to a circumferential element of said drum and spiraling the first strip in a helical manner while pulling longitudinally, slightly tensioning cords of the strip, the uncut edges of the first strip arranged adjacent each other; arranging a second strip of said fabric over said first strip by aligning the bias cut edge of the second strip in a plane parallel with the bias cut edge of said first strip, spiraling the second strip in an opposite helical manner while pulling longitudinally, slightly tensioning cords of the strip, the uncut edges of the second strip arranged adjacent each other, said first and second strips forming a sleeve of plied material; and

circumferentially bevel cutting the plied cord material of said sleeve into bands having edges lying in substantially parallel planes by simultaneously cutting the plied material a first and second time at desired opposite angles in relation to the outside surface of the sleeve to define bands of trapezoidal cross-section and predetermined width with substantially uniform bevel edges where the radially inner band width is greater than the radially outer band width.

2. The method as set forth in claim 1 and further including repeating the steps of spiraling strips of fabric prior to the step of cutting said sleeve into bands.

3. A method of making breaker bands for pneumatic tires comprising the steps of:

rubberizing a length of tire cord material with a heat curable rubber; bias cutting said tire cord material into strips; arranging a first strip of rubberized tire cord material around a building drum by spiraling the first strip in a helical manner while pulling longitudinally, slightly tensioning cords of the strip, the edges of the first strip arranged adjacent each other;

arranging a second strip of tire cord material over said first strip by spiraling the second strip in an opposite helical manner while pulling longitudinally, slightly tensioning cords of the strip, said strips forming a sleeve of plied material; and

circumferentially bevel cutting the plied cord material of said sleeve into bands having edges lying in substantially parallel planes by simultaneously cutting the plied material a first and second time at desired opposite angles in relation to the outsidesurface of the sleeve todefine bands of trapezoidal cross-section and predetermined width with substantially uniform bevel edges where the radially inner band width is greater than the radially outer band width.

4. The method as set forth in claim 3 and further including the steps of spiraling additional strips ofcord material over said sleeve prior to the step of cutting.

5. In a method of making a tire of the type including the steps of:

fabricating a tire carcass;

forming thetire carcass in a torroidal shape;

fabricating a breaker band and uniting it with the expanded carcass; I

applying a tread over the breaker band to define an uncured tire; and

molding and curing the uncured tire under the influence of heat and pressure to form a cured tire; the improvement of fabricating the breaker band which comprises the steps of:

arranging a first strip of rubberized tire cord material around a building drum by spiraling the first strip in a helical manner at a predetermined helical angle ,while pulling longitudinally, slightly tensioning cords of the strip, the edges of the first strip arranged adjacent each other;

arranging a second strip of tire cord material over said first strip by spiraling the second strip in an opposite helical manner at a predetermined helical angle while pulling longitudinally, slightly tensioning cords of the strip, said strips forming a sleeve of plied material; and

circumferentially bevel cutting the plied cord mate- 6. The method as set forth in claim 5 and further including the step of bias cutting strips of said rubberized cord material at a predetermined angle prior to the step of spiraling.

7. The method as set forth in claim 5 and further including the step of plying successive strips of rubberized cord material over said sleeve at successive helical angles prior to circumferentially cutting said sleeve.

8. A method of making breaker bands for pneumatic tires comprising the steps of:

Y bias cutting said tirecord material into strips;

arranging a first strip of rubberized tire cord material around a building drum by spiraling the first strip in a helical manner at a predetermined helical angle while pulling longitudinally, slightly tensioning cords of the strip, the edges of the first strip arranged adjacent each other;

arranging a second strip of tire cord material over said first strip by spiraling the second strip in an opposite helical manner at a predetermined helical angle while pulling longitudinally, slightly tensioning cords of the strip, said strips forming a sleeve of plied material; and

circumferentially bevel cutting the plied cordmaterial of said sleeve into bands having edges lying in substantially parallel planes by simultaneously cutting the plied material a first and second time at desired opposite angles in relation to the outside surface of the sleeve to define bands of trapezoidal cross-section and predetermined width withsubstantially uniform bevel edges where the radially inner band width is greater than the radially outer band width.

9. The method as set forth in claim 8 and further including the step of spiraling a third and fourth strip of rubberized cord material over said sleeve, each successive strip being spiraled as a helix over the preceding strip. 

2. The method as set forth in claim 1 and further including repeating the steps of spiraling strips of fabric prior to the step of cutting said sleeve into bands.
 3. A method of making breaker bands for pneumatic tires comprising the steps of: rubberizing a length of tire cord material with a heat curable rubber; bias cutting said tire cord material into strips; arranging a first strip of rubberized tire cord material around a building drum by spiraling the first strip in a helical manner while pulling longitudinally, slightly tensioning cords of the strip, the edges of the first strip arranged adjacent each other; arranging a second strip of tire cord material over said first strip by spiraling the second strip in an opposite helical manner while pulling longitudinally, slightly tensioning cords of the strip, said strips forming a sleeve of plied material; and circumferentially bevel cutting the plied cord material of said sleeve into bands having edges lying in substantially parallel planes by simultaneously cutting the plied material a first and second time at desired opposite angles in relation to the outside surface of the sleeve to define bands of trapezoidal cross-section and predetermined width with substantially uniform bevel edges where the radially inner band width is greater than the radially outer band width.
 4. The method as set forth in claim 3 and further including the steps of spiraling additional strips of cord material over said sleeve prior to the step of cutting.
 5. In a method of making a tire of the type including the steps of: fabricating a tire carcass; forming the tire carcass in a torroidal shape; fabricating a breaker band and uniting it with the expanded carcass; applying a tread over the breaker band to define an uncured tire; and molding and curing the uncured tire under the influence of heat and pressure to form a cured tire; the improvement of fabricating the breaker band which comprises the steps of: arranging a first strip of rubberized tire cord material around a building drum by spiraling the first strip in a helical manner at a predetermined helical angle while pulling longitudinally, slightly tensioning cords of the strip, the edges of the first strip arranged adjacent each other; arranging a second strip of tire cord material over said first strip by spiraling the second strip in an opposite helical manner at a predetermined helical angle while pulling longitudinally, slightly tensioning cords of the strip, said strips forming a sleeve of plied material; and circumferentially bevel cutting the plied cord material of said sleeve into bands having edges lying in substantially parallel planes by simultaneously cutting the plied material a first and second time at desired opposite angles in relation to the outside surface of the sleeve to define bands of trapezoidal cross-section and predetermined width with substantially uniform bevel edges where the radially inner band width is greater than the radially outer band width.
 6. The method as set forth in claim 5 and further including the step of bias cutting strips of said rubberized cord material at a predetermined angle prior to the step of spiraling.
 7. The method as set forth in claim 5 and further including the step of plying successive strips of rubberized cord material over said sleeve at successive helical angles prior to circumferentially cutting said sleeve.
 8. A method of making breaker bands for pneumatic tires comprising the steps of: bias cutting said tire cord material into strips; arranging a first strip of rubberized tire cord material around a building drum by spiraling the first strip in a helical manner at a predetermined helical angle while pulling longitudinally, slightly tensioning cords of the strip, the edges of the first strip arranged adjacent each other; arranging a second strip of tire cord material over said first strip by spiraling the second strip in an opposite helical manner at a predetermined helical angle while pulling longitudinally, slightly tensioning cords of the strip, said strips forming a sleeve of plied material; and circumferentially bevel cutting the plied cord material of said sleeve into bands having edges lying in substantially parallel planes by simultaneously cutting the plied material a first and second time at desired opposite angles in relation to the outside surface of the sleeve to define bands of trapezoidal cross-section and predetermined width with substantially uniform bevel edges where the radially inner band width is greater than the radially outer band width.
 9. The method as set forth in claim 8 and further including the step of spiRaling a third and fourth strip of rubberized cord material over said sleeve, each successive strip being spiraled as a helix over the preceding strip. 